Fabric bearing design and process for producing same

ABSTRACT

Provided is a fabric having a novel design in which an uneven-surface design is partially formed by embossing. A polyurethane resin is applied to the surface of the fabric having, on the surface, a low fineness portion and a high fineness portion having a higher single fiber fineness than that of the low fineness portion, the fabric is dried; and embossing is performed on the surface of the fabric. By performing the embossing, while an uneven-surface design is not imparted to the high fineness portion by the embossing and a non-uneven-surface design portion  3  is formed, the uneven-surface design is imparted to the low fineness portion by the embossing and an uneven-surface design portion  2  is formed.

TECHNICAL FIELD

The present invention relates to a fabric partially having anuneven-surface design and a process for producing the same.

BACKGROUND ART

As a method for imparting an uneven-surface design to a fabric,embossing is known. Embossing is to form an uneven-surface design bypressing a heated mold (referred to as an embossing mold) having anuneven-surface pattern reverse to a desired uneven-surface design(uneven-surface pattern) against the surface of a fabric, and in therelated art, various methods have been proposed (for example, PTLs 1 and2 below). When the uneven-surface design is imparted by the embossing inthe related art, the uneven-surface design is uniformly imparted to theentire surface of the fabric, and the uneven-surface design is notpartially formed by the embossing.

CITATION LIST Patent Literature

[PTL 1] JP-A-2010-7211

[PTL 2] JP-A-2010-248668

SUMMARY OF INVENTION Technical Problem

An object of the present invention is to provide a fabric having a noveldesign in which an uneven-surface design is partially formed byembossing.

Solution to Problem

First, the present invention provides a process for producing a fabricbearing a design partially having an uneven-surface design by embossing,the process including: applying a polyurethane resin to a surface of afabric having, on the surface, a low fineness portion and a highfineness portion having a higher single fiber fineness than that of thelow fineness portion; drying the fabric; and performing embossing on thesurface of the fabric.

Second, the present invention provides a fabric bearing a designincluding: a polyurethane resin which is present on a surface portion ofthe fabric; an uneven-surface design portion and a non-uneven-surfacedesign portion on the surface portion, in which the uneven-surfacedesign portion is constituted by threads having a lower single fiberfineness than that of the non-uneven-surface design portion, and anuneven-surface design is imparted to a surface of the uneven-surfacedesign portion by embossing, and the non-uneven-surface design portionis constituted by threads having a higher single fiber fineness thanthat of the uneven-surface design portion, and the uneven-surface designis not imparted to a surface of the non-uneven-surface design portion bythe embossing.

Advantageous Effects of Invention

According to the present invention, a fabric having a novel design inwhich an uneven-surface design is partially formed can be producedwithout complex processes.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a plan view schematically illustrating an example of a surfacedesign of a fabric according to an embodiment.

FIG. 2 is a photograph of the cross-section in an uneven-surface designportion of the fabric according to the embodiment.

FIG. 3 is a photograph of the cross-section in a non-uneven-surfacedesign portion of the fabric according to the embodiment.

FIG. 4 is a photograph of the surface in the uneven-surface designportion of the fabric according to the embodiment.

FIG. 5 is a photograph of the surface of the uneven-surface designportion before resin processing.

FIG. 6 is a photograph of the surface in the non-uneven-surface designportion of the fabric according to the embodiment.

FIG. 7 is a photograph of the surface of the non-uneven-surface designportion before the resin processing.

FIG. 8 is an explanatory view showing a knitted weave according toExample 14.

DESCRIPTION OF EMBODIMENTS

Hereinafter, embodiments of the present invention will be described indetail.

In a process for producing a fabric bearing a design according to thepresent invention, a polyurethane resin is applied to the surface of thefabric having a low fineness portion and a high fineness portion on thesurface, and the resultant is dried and is thereafter subjected toembossing on the surface. In the low fineness portion having a lowsingle fiber fineness, the voids between fibers are small, the fibersare fixed together by the polyurethane resin, and thus shapingproperties are improved. Therefore, an uneven-surface design can beimparted by embossing. On the other hand, in the high fineness portionhaving a high single fiber fineness, the voids between fibers are large,and the fibers are brought into a state close to spot joining ratherthan being fixed together by the polyurethane resin. Therefore, in thehigh fineness portion, even when embossing is performed thereon, theuneven-surface design is not imparted thereto, and the design of thefabric itself can remain. That is, by performing the embossing, theuneven-surface design is imparted to the low fineness portion by theembossing and thereby an uneven-surface design portion can be formed,while the uneven-surface design is not imparted to the high finenessportion by the embossing and thereby a non-uneven-surface design portionis formed. Therefore, the fabric partially having the uneven-surfacedesign formed by the embossing can be produced without complexprocesses.

As the fabric as a processing object (that is, a raw fabric or basefabric), a fabric having a low fineness portion and a high finenessportion on the surface thereof is used. A part in which the single fiberfineness of threads exposed to the surface of the fabric is low isreferred to as the low fineness portion, and a part in which the singlefiber fineness of threads exposed to the surface of the fabric is highis referred to as the high fineness portion. A single fiber fineness isthe fineness of a single fiber or filament included in a thread and isalso referred to as a filament fineness. The single fiber fineness ofthe portions other than the surface portion, such as the rear face ofthe fabric is not particularly limited, and the low fineness portion andthe high fineness portion are concepts used for the surface portion(that is, surface layer portion) of the fabric. Here, “high” and “low”in the high fineness portion and the low fineness portion are intendedto express the relationship between relative finenesses of the twofineness portions. That is, this means that the high fineness portionhas a higher single fiber fineness than that of the low fineness portion(conversely, the low fineness portion has a lower single fiber finenessthan that of the high fineness portion).

The low fineness portion is a part constituted by threads having a lowersingle fiber fineness than that of the high fineness portion in thesurface portion of the fabric, and this part becomes the uneven-surfacedesign portion by the embossing. In the present invention, it is notnecessary that all of the threads constituting the low fineness portionhave a lower single fiber fineness than that of the threads constitutingthe high fineness portion, and the threads mainly constituting the lowfineness portion may have a lower single fiber fineness than that of thethreads mainly constituting the high fineness portion. Here, “mainlyconstituting” means constituting 70% or more (volume ratio) of thethreads exposed on the surface of the fabric, and more preferablyconstituting 80% or more. It is preferable that the low fineness portionincludes threads having a single fiber fineness of 1.5 dtex or lower,that is, the single fiber fineness of the threads constituting the lowfineness portion is 1.5 dtex or lower. In other words, it is desirablethat the threads mainly exposed to the surface in the low finenessportion have a single fiber fineness of 1.5 dtex or lower. By causingthe single fiber fineness of the threads constituting the low finenessportion to be 1.5 dtex or lower, the voids between the fibersconstituting the low fineness portion can be reduced, and the effect offixing the fibers together by the polyurethane resin can be enhanced.Accordingly, the shaping properties of the uneven-surface design formedby the embossing can be enhanced. The single fiber fineness of thethreads constituting the low fineness portion is preferably 1.0 dtex orlower, and more preferably 0.7 dtex or lower. The lower limit of thesingle fiber fineness is not particularly limited, and is preferably 0.1dtex or higher.

The high fineness portion is a part constituted by threads having ahigher single fiber fineness than that of the low fineness portion inthe surface portion of the fabric, and this part becomes thenon-uneven-surface design portion. It is preferable that the highfineness portion includes threads having a single fiber fineness ofhigher than 1.5 dtex, that is, the single fiber fineness of the threadsconstituting the high fineness portion is higher than 1.5 dtex. In otherwords, it is desirable that the threads mainly exposed to the surface inthe high fineness portion have a single fiber fineness of higher than1.5 dtex. By causing the single fiber fineness of the threadsconstituting the high fineness portion to be higher than 1.5 dtex, thevoids between the fibers constituting the high fineness portion can beenlarged, and the effect of fixing the fibers together by thepolyurethane resin can be reduced. Accordingly, the uneven-surfacedesign cannot be easily shaped by the embossing. In order to moreeffectively suppress the shaping of the uneven-surface design in thehigh fineness portion, the single fiber fineness of the threadsconstituting the high fineness portion is preferably 2.3 dtex or higher,and more preferably 2.5 dtex or higher. Although the upper limit of thesingle fiber fineness thereof is not particularly limited, when thethreads are monofilaments, the upper limit is preferably 2000 dtex orlower, and when the threads are multifilaments, the upper limit ispreferably 10 dtex or lower.

The difference in single fiber fineness between the low fineness portionand the high fineness portion is preferably 0.4 dtex or higher, morepreferably 0.5 dtex or higher, further preferably 1.0 dtex or higher,and even more preferably 2.0 dtex or higher. Accordingly, a more clearchange in design can be clearly provided between the uneven-surfacedesign portion and the non-uneven-surface design portion.

It is preferable that the fineness of the threads constituting the lowfineness portion (that is, the total fineness, also called the yarnfineness) is set to be equal to or more than the total fineness of thethreads constituting the high fineness portion. Accordingly, the lowfineness portion is densely filled with fine fibers having a low singlefiber fineness, and thus the voids between the fibers can be reduced.

The fabric having the low fineness portion and the high fineness portionon the surface portion as described above may be a woven fabric or aknitted fabric and may be selected appropriately depending onapplications. In addition, a method for forming the low fineness portionand the high fineness portion is also not particularly limited.

For example, in the case of the woven fabric, by using a thread having alow single fiber fineness as one of the warp and the weft and a threadheaving a high single fiber fineness as the other, these may be woveninto a weave of a warp satin and a weft satin. Accordingly, the lowfineness portion in which the threads having a low single fiber finenessare mainly exposed to the surface and the high fineness portion in whichthe threads having a high single fiber fineness are mainly exposed tothe surface can be provided by the warp satin portion and the weft satinportion.

In other weaves, similarly, the low fineness portion in which thethreads having a low single fiber fineness are mainly exposed to thesurface and the high fineness portion in which the threads having a highsingle fiber fineness are mainly exposed to the surface can be providedby a yarn structure of threads having a low single fiber fineness andthreads having a high single fiber fineness using the warp and the weft.

In the case of the knitted fabric, like the woven fabric, by knittingthe configuration of the low fineness portion and the high finenessportion by combining a knitted weave and a yarn structure using threadshaving a low single fiber fineness and threads having a high singlefiber fineness, the low fineness portion in which the threads having alow single fiber fineness are mainly exposed to the surface and the highfineness portion in which the threads having a high single fiberfineness are mainly exposed to the surface can be provided.

In the fabric as the processing object, in the case of the woven fabric,the total fineness per unit volume 1 mm³ is preferably 2500 to 5800dtex, more preferably 3000 to 5800 dtex, and even more preferably 3500to 5800 dtex. By causing this value to be 2500 dtex or higher, the voidsbetween the fibers can be reduced, and the shaping properties of theuneven-surface design formed by embossing can be improved. Furthermore,by causing this value to be 5800 dtex or lower, good weaving propertiescan be secured.

The total fineness per unit volume 1 mm³ is calculated as follows. Bythe product of a warp density (pieces/25.4 mm), a warp fineness (threadfineness) (dtex), and 25.4 mm, the total fineness in a volume of 25.4 mmin a width direction with respect to a gray fabric longitudinaldirection×25.4 mm in a longitudinal direction×a fabric thickness (mm) iscalculated. In this multiplying, assuming that the warp extends straightin the gray fabric longitudinal direction, 25.4 mm is multiplied. Thetotal weft fineness is calculated in the same manner as the warp, andthe sum of the total warp fineness and the total weft fineness iscalculated. The quotient of the calculated value divided by the volume(width direction×longitudinal direction×fabric thickness) is calculatedto be used as the total fineness per 1 mm³. The above expression isappropriately changed in consideration of yarn drawing or a weave. Forexample, when the yarn drawing is 1 in 3 out (that is, a structure ofone yarn in and three yarns out), 1/4 is further multiplied.

Specifically, this is calculated by the following expression.

Total fineness per unit volume 1 mm³=(warp density×warp fineness(threadfineness)×25.4+weft density×weft fineness(threadfineness)×25.4)/(25.4×25.4×fabric thickness (mm))

In the fabric as the processing object, in the case of the knittedfabric, the total fineness per unit volume 1 mm³ is preferably 1000 to5800 dtex, more preferably 1200 to 5800 dtex, and even more preferably1500 to 5800 dtex. By causing this value to be 1000 dtex or higher, thevoids between the fibers can be reduced, and the shaping properties ofthe uneven-surface design formed by embossing can be improved.Furthermore, by causing this value to be 5800 dtex or lower, goodknitting properties can be secured.

The total fineness per unit volume 1 mm³ in the case of the knittedfabric is calculated as follows. By the product of twice a coursedensity, the thread fineness, and 25.4 mm, the total fineness in avolume of the width direction (25.4 mm) with respect to the gray fabriclongitudinal direction×the longitudinal direction (25.4 mm)×the fabricthickness (mm) is calculated. Since two cross-sections are shown in oneloop in a cross-section perpendicular to the gray fabric longitudinaldirection, the warp density is doubled in the calculation. In addition,it is assumed that a horizontal cross-section continues for 25.4 mm inthe width direction. The quotient of the calculated value divided by thevolume (width direction×longitudinal direction×fabric thickness) iscalculated to be used as the total fineness per 1 mm³. In a case ofmultiple weaves, for each of yarns constituting each weave, the yarnfineness in a volume of a gray fabric width direction (25.4 mm)×the grayfabric longitudinal direction (25.4 mm)×the fabric thickness (mm) iscalculated, and thereafter the calculated values are added. The quotientof the added value divided by the volume is calculated, therebyobtaining the total fineness per unit volume 1 mm³. The above expressionis appropriately changed in consideration of yarn drawing or a weave.For example, when the yarn drawing is 1 in 3 out, 1/4 is furthermultiplied.

Specifically, this is calculated by the following expressions.

Total fineness per unit volume 1 mm³ (in a case of tricot knitting andcircular knitting)=(total fineness^(*1) for each yarn×coursedensity×2×25.4)/(25.4×25.4×fabric thickness (mm))

*1: The total yarn fineness of a front yarn, a middle yarn, and a backyarn in the tricot knitting, and the total yarn fineness of a face yarn,a bonding yarn, and a rear yarn in the circular knitting.

Total fineness per unit volume 1 mm³ (in a case of a double raschelopened product)={(total fineness for each ground yarn+total fineness foreach pile yarn)×course density×2×25.4}/(25.4×25.4×fabric thickness (mm))

Total fineness per unit volume 1 mm³ (in a case of a double raschelunopened product)={(total fineness for each ground yarn+total yarnfineness for each connecting yarn×2)×coursedensity×2×25.4}/(25.4×25.4×fabric thickness (mm))

The material of the fibers constituting the fabric as the processingobject is not particularly limited, and well-known fibers such asnatural fibers, regenerated fibers, semi-synthetic fibers, and syntheticfibers may be used, and these fibers may be used in combination of twoor more types by techniques such as blending, combining, twisting, mixedweaving, and mixed knitting. A thermoplastic fiber is preferable fromthe viewpoints of the shaping properties and durability of theuneven-surface design. As the thermoplastic fiber, synthetic fibers suchas polyester, polypropylene, and nylon, and semi-synthetic fibers suchas acetate and triacetate may be employed. These may be used singly orin combination of two or more types. Among these, polyester is morepreferable, and polyethylene terephthalate is particularly preferablefor excellent physical properties.

The form of the threads constituting the fabric may be any of a spunyarn (short fiber yarn), a multifilament yarn, and a monofilament yarn(both are long fiber yarns), and may be a long and short fiber compositespun yarn which is a combination of a long fiber and a short fiber. Themultifilament yarn may be subjected to twisting if necessary, or may besubjected to processing such as false twisting or a fluid disturbancetreatment.

In addition, the fabric may be subjected to a pre-treatment such asraising, dyeing, presetting, or scouring, if necessary. In the case ofraising, it is preferable to cut and raise the threads which are exposedto the surface of the low fineness portion and have a low single fiberfineness because the uneven-surface design can be more easily shaped bythe embossing.

The polyurethane resin used in the present invention is not particularlylimited, and examples thereof include polyurethane resins based onpolyether, polyester, polycarbonate, and the like. Among these, from theviewpoint of texture, a polyester-based polyurethane resin is preferablyused, and from the viewpoint of durability, particularly wearresistance, a polycarbonate-based polyurethane resin is preferably used.

The softening temperature of the polyurethane resin is preferably 100°C. to 200° C. By causing the softening temperature to be 100° C. orhigher, even in a case of being used under conditions in which thefabric is left for a long period of time at a high temperature such asin a vehicle interior material, the resin can be less likely to melt. Bycausing the softening temperature to be 200° C. or lower, an embossingroll does not need to be set to an excessively high temperature when theuneven-surface design is shaped, and the basic fabric in a part to whichthe polyurethane resin is not applied can be prevented from becomingcoarse and hard. The softening temperature is measured by differentialscanning calorimetry using a DSC thermal analyzer.

The application of the polyurethane resin is performed on the entiresurface of the fabric having the low fineness portion and the highfineness portion on the surface. The application amount of thepolyurethane resin varies depending on the configuration of the fabricas the processing object, for example, density, fineness, and the like,but is preferably about 1 to 200 g/m² with respect to the fabric, morepreferably 5 to 150 g/m², and even more preferably 10 to 100 g/m². Inthe fabric bearing a design according to this embodiment, thepolyurethane resin permeates between the fibers at least in the surfaceportion (surface layer portion) of the fabric to form the surface of thefabric together with the fibers, and unlike a grain face syntheticleather, the skin layer of the polyurethane resin alone is not formedover the entire surface of the fabric. The application amount of thepolyurethane resin is obtained by converting the application amount inthe part to which the polyurethane resin is applied into the applicationamount per square meter and is a value in terms of the weight of a solidcontent after being dried.

More specifically, a treatment liquid containing the polyurethane resinis applied to one side of the fabric. The treatment liquid contains atleast the polyurethane resin and a medium for dispersing thepolyurethane resin, for example, water, and if necessary, may containadditives such as a coloring material (dye, pigment, or metal powder),or a thickener. A method for applying the treatment liquid is notparticularly limited, and examples thereof include screen printing,rotary printing, ink jet printing, and the like. In a case where thefabric has an uneven surface, a reverse coater, a comma coater, or thelike may also be used.

Next, the polyurethane resin is dried and solidified. The drying may beperformed to the extent that the medium does not remain, and theconditions thereof are not particularly limited, and may beappropriately set in consideration of the boiling point of the mediumand production efficiency.

As described above, after the polyurethane resin is applied to thesurface portion of the fabric and dried, the entire surface is subjectedto embossing. Specifically, for example, the surface is caused to passthrough an embossing roll having a temperature of 100° C. to 160° C. anda pressure (linear pressure) of 490 to 1960 N/cm to soften and shape thepolyurethane resin on the surface of the fabric. On the surface of theembossing roll, an uneven-surface pattern having an uneven surfacereverse to a desired fine uneven-surface pattern is carved. Thetemperature of the embossing roll is set in consideration of thesoftening temperature of the polyurethane resin, the material of thefibers constituting the fabric, required durability, and the like.

A heat treatment may be performed on the fabric after the shapingprocess in order to soften the texture. The heat treatment is preferablyperformed at 100° C. to 150° C. for 30 seconds to 3 minutes.

As described above, the fabric bearing a design, which partially has theuneven-surface design, can be obtained. The polyurethane resin ispresent on the surface portion of the fabric bearing a design accordingto the embodiment, and the surface portion has the uneven-surface designportion and the non-uneven-surface design portion. The polyurethaneresin is present over the entire surface of the fabric together with thefibers, and the surface of the fabric is formed by the polyurethaneresin and the fibers. The polyurethane resin permeates between thefibers at least in the surface portion of the fabric in the thicknessdirection such that a polyurethane resin permeation portion is formed atleast in the surface portion of the fabric.

FIG. 1 schematically shows an example of a surface design of the fabricbearing a design according to the embodiment. A fabric bearing a design1 has, in its surface portion, an uneven-surface design portion 2 towhich an uneven-surface design having an embossed pattern is impartedand a non-uneven-surface design portion 3 to which the uneven-surfacedesign having an embossed pattern is not imparted. The uneven-surfacedesign portion 2 and the non-uneven-surface design portion 3 arerepeatedly provided in a predetermined pattern over the entire surfaceof the fabric 1 to form a repeated pattern. In this example, a hexagonalpattern is formed by the uneven-surface design portion 2 surrounding theperiphery of the hexagonal non-uneven-surface design portion 3. Theuneven-surface design portion 2 and the non-uneven-surface designportion 3 may be formed in a manner opposite to the configuration shownin FIG. 1. In addition, the shape, number, and arrangement thereof arenot particularly limited and various modifications are possible.

The uneven-surface design portion is formed by the low fineness portion,and the non-uneven-surface design portion is formed by the high finenessportion. Therefore, the uneven-surface design portion is constituted bythe threads having a lower single fiber fineness than that of thenon-uneven-surface design portion, and the non-uneven-surface designportion is constituted by the threads having a higher single fiberfineness than that of the uneven-surface design portion.

In the uneven-surface design portion, adjacent fibers are more firmlyfixed together by the polyurethane resin than in the non-uneven-surfacedesign portion, so that the uneven-surface design is imparted to thesurface by the embossing. Specifically, in the low fineness portion,since the fibers constituting the low fineness portion are thin, thespaces between the fibers are small and the spaces are easily filledwith the polyurethane resin. Accordingly, the fibers are brought into astate of being fixed together by the polyurethane resin (see FIG. 2).Therefore, the low fineness portion can be easily shaped together withthe polyurethane resin when performing embossing, and the uneven-surfacedesign can be imparted thereto by the embossing. The uneven-surfacedesign formed by the embossing is not particularly limited, and adesired uneven-surface shape such as a leather-like grain pattern or ageometric pattern may be imparted.

On the other hand, in the non-uneven-surface design portion, adjacentfibers are more loosely fixed together by the polyurethane resin thanthe uneven-surface design portion, so that the uneven-surface design isnot imparted to the surface by the embossing. Specifically, in the highfineness portion, since the fibers constituting the high finenessportion are thick, the spaces between the fibers are large, and in thesame amount of the resin, the voids which are not filled with thepolyurethane resin are greater than those in the low fineness portion.Therefore, the fibers are brought into a state in which the adjacentfibers are spot-joined by the polyurethane resin rather than being fixedtogether by the polyurethane resin (see FIG. 3). Therefore, even whenthe embossing is performed, the uneven-surface design is not imparted,and the design of the fabric itself can be left. That is, thenon-uneven-surface design portion is a part to which the uneven-surfacedesign formed by the embossing is not imparted, and may also have anuneven-surface pattern formed by the threads of a weave in a wovenfabric or knitted fabric as long as the uneven-surface pattern is anuneven-surface pattern which is not formed by embossing.

In this embodiment, it is preferable that the polyurethane resin isimparted so that, in the low fineness portion (that is, theuneven-surface design portion), the permeation thickness of thepolyurethane resin is 40 to 400 μm, the filling ratio of thepolyurethane resin is 10% to 55%, and the filling ratio of the fibers is45% to 80%.

That is, in the uneven-surface design portion, the permeation thicknessof the polyurethane resin is preferably in a range of 40 to 400 μm, morepreferably 40 to 330 μm, even more preferably 40 to 260 μm, andparticularly preferably 50 to 200 μm. By setting the permeationthickness to be in such a range, the shaping properties by the embossingcan be improved. Here, the permeation thickness of the polyurethaneresin is obtained by taking a photograph of a vertical section of thepolyurethane resin permeation portion with a microscope, measuring thelength in a vertical direction from the surface of the fabric to thepermeation lower end of the polyurethane resin at arbitrary ten points,and calculating the average value thereof.

As described above, the polyurethane resin permeates between the fibersat least in the surface portion of the fabric and may permeatethroughout the fabric thickness. However, from the viewpoint of texture,it is preferable that the polyurethane resin does not permeate throughthe entire thickness of the fabric. That is, it is preferable that anon-permeation portion is present below the polyurethane resinpermeation portion. Specifically, in the uneven-surface design portion,the ratio of the permeation thickness of the polyurethane resin to thethickness of the fabric bearing a design may be 5% to 25%, or may be 10%to 20%. In the non-uneven-surface design portion, the permeationthickness of the polyurethane resin is not particularly limited.However, typically, since the voids between the fibers therein arelarge, the permeation thickness thereof is greater than the permeationthickness in the uneven-surface design portion, and may be, for example,100 to 500 μm, 130 to 400 μm, or 150 to 300 μm. In thenon-uneven-surface design portion, the ratio of the permeation thicknessof the polyurethane resin to the thickness of the fabric bearing adesign is preferably higher than the ratio of the permeation thicknessin the uneven-surface design portion, and may be, for example, 21% to55%, 26% to 55%, or 30% to 55%. Here, the thickness of the fabricbearing a design is not particularly limited, and may be, for example,0.2 to 3.0 mm (that is, 200 to 3000 μm), or 0.3 to 2.8 mm. The numericalranges of the ratio of the permeation thickness and the thickness of thefabric bearing a design are examples for a fabric excluding doubleraschel unopened products.

In addition, in the uneven-surface design portion, the filling ratio ofthe polyurethane resin is preferably in a range of 10% to 55%, morepreferably 15% to 50%, and even more preferably 20% to 45%. By causingthe filling ratio of the polyurethane resin to be 10% or more, theshaping properties by the embossing can be improved. By causing thefilling ratio thereof to be 55% or less, flexibility can be improved.

The filling ratio of the polyurethane resin is the proportion occupiedby the polyurethane resin in the polyurethane resin permeation portion(a part in which the polyurethane resin permeates between the fibers),and is obtained as follows. That is, this is obtained by the followingexpression from the filling ratio of the fibers and the void ratio,which will be described later.

Filling ratio (%) of polyurethane resin=100−(filling ratio offibers+void ratio)

In the uneven-surface design portion, the filling ratio of the fibers ispreferably in a range of 45% to 80%, more preferably 50% to 80%, andeven more preferably 55% to 80%. By causing the filling ratio of thefibers to be 45% or more, the voids between the fibers can be reducedand thus the adhesion between the fibers can be improved, therebyimproving the wear resistance. By causing the filling ratio of thefibers to be 80% or less, the flexibility can be improved. The fillingratio of the fibers in the non-uneven-surface design portion is notparticularly limited, but is preferably 50% or less, and more preferably20% to 45%. Typically, since the single fiber fineness of the fibersconstituting the non-uneven-surface design portion is high and the voidsbetween the fibers are large, the filling ratio of the fibers therein islower than that in the uneven-surface design portion.

The filling ratio of the fibers is the proportion occupied by the fibersin the polyurethane resin permeation portion, and is obtained asfollows. That is, the photograph of the vertical section of thepolyurethane resin permeation portion taken with the microscope is readby a scanner, and the number (n) of yarn sections in a measurement areahaving a width of 100 μm as the lateral direction and having thepermeation thickness of the polyurethane resin in the vertical directionis measured, and the filling ratio of the fibers is obtained by thefollowing expression. The diameter R (μm) of the yarn is obtained bymeasuring the diameters in the vertical and lateral directions of thecross-section of the yarn at arbitrary five points and averaging themeasured values. The filling ratio of the fibers is the average value ofthe filling ratios calculated by the following expression at arbitraryfive points.

Filling ratio (%) of fibers=(78.5×R ² ×n)(100×permeation thickness (μm)of polyurethane resin)

In this embodiment, it is preferable that the polyurethane resin isapplied so that the void ratio in the high fineness portion (that is,the non-uneven-surface design portion) is 10% or more and is higher thanthe void ratio in the low fineness portion (that is, the uneven-surfacedesign portion). That is, the void ratio in the non-uneven-surfacedesign portion is preferably 10% or more, and more preferably 15% ormore. By causing the void ratio to be 10% or more, the uneven-surfaceshape cannot be easily shaped by the embossing, and a more clear changein design can be provided between the uneven-surface design portions.The upper limit of the void ratio in the non-uneven-surface designportion is not particularly limited, but it is typically 30% or less,and more preferably 20% or less. The void ratio in the uneven-surfacedesign portion is lower than the void ratio in the non-uneven-surfacedesign portion and is not particularly limited, but is preferably lessthan 10%, and more preferably 7% or less.

Here, the void ratio is the proportion of the voids in the polyurethaneresin permeation portion, and is obtained as follows. That is, thephotograph of the vertical section of the polyurethane resin permeationportion taken with the microscope is read by the scanner, and the voidsand the other parts in the measurement area having a width of 100 μm inthe lateral direction and having the permeation thickness of thepolyurethane resin in the vertical direction are binarized, and theproportion of the voids in the polyurethane resin permeation portion iscalculated. The void ratio in the polyurethane resin permeation portionis the average value of the void ratios calculated at arbitrary fivepoints.

In this embodiment, the ratio of the fibers to the polyurethane resin(fibers/polyurethane resin) in the uneven-surface design portion ispreferably 1.0 or more, and more preferably 1.25 or more. By causing theratio to be 1.0 or more, the number of fibers per polyurethane resin canbe increased, the fixing effect by the polyurethane resin can beincreased, the shaping properties of the uneven-surface design formed bythe embossing can be improved, and durability can be improved. The ratiois obtained by calculating the respective areas by the product of eachof the filling ratios of the fibers and the polyurethane resincalculated above and the measurement area and calculating the quotientof the area of the fibers divided by the area of the polyurethane resin.The ratio of the fibers to the polyurethane resin (fiber/polyurethaneresin) in the non-uneven-surface design portion is smaller than theratio in the uneven-surface design portion, and is preferably less than1.0, and more preferably less than 0.8.

In this embodiment, the sum of the outer circumferential lengths of thefiber cross-sections in the uneven-surface design portion is preferably1500 μm or more per unit area 10,000 μm², and more preferably 2000 μm ormore. When the sum of the outer circumferential lengths of the fibercross-sections is 1500 μm or more, the adhesion between the polyurethaneresin and the fibers is improved, the compression resilience of thefibers is suppressed, and thus the shaping properties of theuneven-surface shape formed by embossing can be improved. It is thoughtthat this is because as the sum of the outer circumferential lengthsincreases, a large number of fibers (filaments) having a small singlefiber fineness are present, the voids between the fibers are small, andthe polyurethane resin and the fibers are easily fixed together.Furthermore, it is thought that a large number of fibers having a smallsingle fiber fineness result in an increase in the surface area withrespect to the total fineness, and thus the area covered with thepolyurethane resin is increased and is easily fixed. The upper limit ofthe sum of the outer circumferential lengths of the fiber cross-sectionsis not particularly limited, and may be, for example, 9000 μm or less,or 6000 μm or less. It is preferable that the sum of the outercircumferential lengths of the fiber cross-sections in thenon-uneven-surface design portion is less than the value in theuneven-surface design portion.

The sum of the outer circumferential lengths of the fiber cross-sectionsis obtained as follows. That is, the photograph of the vertical sectionof the polyurethane resin permeation portion taken with the microscopeis read by the scanner, and the number (n) of yarn sections in themeasurement area having a width of 100 μm in the lateral direction andhaving the permeation thickness of the polyurethane resin in thevertical direction is measured, and the sum of the outer circumferentiallengths of the fiber cross-sections is obtained by the followingexpression. The diameter R (μm) of the yarn is obtained by measuring thediameters in the vertical and lateral directions of the cross-section ofthe yarn at arbitrary five points and averaging the measured values. Thesum of the outer circumferential lengths of the fiber cross-sections isthe average value of the sums of the outer circumferential lengthscalculated at arbitrary five points.

Sum (μm) of outer circumferential lengths of fibercross-sections=(31,400×R×n)÷(100×permeation thickness of polyurethaneresin (μm))

FIG. 2 shows the cross-section in the uneven-surface design portion ofthe fabric bearing a design according to this embodiment, and is aphotograph of the vertical section of the polyurethane resin permeationportion on the surface side of the fabric, taken with a microscope(Digital HF Microscope VH-8000 manufactured by Keyence Corporation, thesame is applied hereinafter). The part surrounded by the rectangularframe in the photograph is the measurement range used when the fillingratio and the void ratio are measured, the measurement width is 100 μm,and the height is the permeation thickness of the polyurethane resin.FIG. 3 is a photograph of the vertical section of the non-uneven-surfacedesign portion of the fabric described above, taken with a microscope.Like FIG. 2, the part surrounded by the rectangular frame in thephotograph is the measurement range used when the filling ratio and thevoid ratio are measured, the measurement width is 100 μm, and the heightis the permeation thickness of the polyurethane resin. When thepermeation thickness, the filling ratio, the void ratio, and the likeare measured using these photographs, in order to reduce variations inthe measurement position, the average value of five points or ten pointsrandomly extracted from the thread part in which the fibers form a lumpstate (that is, excluding the boundary part between the threads) iscalculated.

FIG. 4 is a photograph of the surface of the uneven-surface designportion (single fiber fineness: 0.6 dtex) of the fabric bearing a designaccording to an embodiment, and FIG. 5 is a photograph of the surfacebefore resin processing, both of which are taken with the microscope ata magnification of 100 times. In the low fineness portion, while a largenumber of filaments are clearly shown before the resin processing shownin FIG. 5, there is a clear change in the shape of the surface after theresin processing and embossing shown in FIG. 4 and each filament is notclearly shown.

FIG. 6 is a photograph of the surface of the non-uneven-surface designportion (single fiber fineness: 7.5 dtex) of the fabric described above,and FIG. 7 is a photograph of the surface before the resin processing,both of which are taken with the microscope at a magnification of 100times. In the high fineness portion, there is hardly any change in theshape of the surface before the resin processing shown in FIG. 7 andafter the resin processing and embossing shown in FIG. 6.

According to this embodiment described above, a fabric which partiallyhas an uneven-surface design formed by embossing without complexprocesses and has the design of the fabric itself remaining in the otherparts can be produced, and thus a fabric having a special design thathas not yet been seen can be produced at low costs.

The application of the fabric bearing a design of the present inventionis not particularly limited, and can be used in various fields such asvehicle interior materials, interior materials, clothing, bags, and thelike.

EXAMPLES

[Evaluation Method]

(1) Shaping Properties

Regarding products subjected to embossing using embossing rolls A, B,and C having the following uneven-surface shapes, uneven-surface designportions and non-uneven-surface design portions were visually checkedand evaluated according to the following evaluation criteria. Regardingthe following recess shape, the pattern spacing is the distance betweenthe apexes of adjacent protrusions, and the inclination angle is theangle between the straight line connecting the highest position of theprotrusion to the lowest position of the recess and a tangent to thehighest position of the protrusion.

Embossing roll A: recess width 800 μm, maximum recess depth 150 μm,pattern spacing 2000 μm, uneven-surface cross-sectional shape invertical direction; corrugated, inclination angle 5 to 20 degrees,leather grain pattern

Embossing roll B: recess width 1200 μm, maximum recess depth 250 μm,pattern spacing 5000 μm, uneven-surface cross-sectional shape invertical direction; corrugated, inclination angle 10 to 30 degrees,leather grain pattern

Embossing roll C: recess width 1500 μm, maximum recess depth 450 μm,pattern spacing 10,000 μm, uneven-surface cross-sectional shape invertical direction; trapezoidal, line pattern

(Evaluation Criteria)

1: All the uneven-surface shapes of A, B, and C are clearly shaped.

2: The uneven-surface shape of A is unclear, but the uneven-surfaceshapes of B and C are clearly shaped.

3: The uneven-surface shapes of A and B are unclear, but theuneven-surface shape of C is clearly shaped.

4: All the uneven-surface shapes of A, B, and C are unclear.

(2) Design Properties

After evaluating the shaping properties, the uneven-surface designportions and the non-uneven-surface design portions of the products werevisually observed and evaluated according to the following evaluationcriteria.

(Evaluation Criteria)

1: The uneven-surface shape is clearly shaped by the embossing in theuneven-surface design portion, and the uneven-surface shape is not seenin the non-uneven-surface design portion, so that two types of designsare clearly obtained.

2: Although the uneven-surface shape is clearly shaped by the embossingin the uneven-surface design portion, the uneven-surface shape formed bythe embossing is unclearly seen in the non-uneven-surface designportion. Otherwise, the uneven-surface shape is not seen in thenon-uneven-surface design portion, but the uneven-surface shape of theuneven-surface design portion is unclear. Therefore, although clarity isdegraded, two types of designs are obtained.

3: The uneven-surface shape is clearly shaped in both. Otherwise, bothare unclear, and two types of designs are not obtained.

Example 1

A polyethylene terephthalate false twisted yarn (single fiber fineness:7.42 dtex) of 178 dtex/24 f was used as a warp, a polyethyleneterephthalate false twisted yarn (single fiber fineness: 1.16 dtex) of333 dtex/288 f was used as a weft, and these were woven into a weavehaving a 12-harness weft satin as an uneven-surface design portion andhaving a 12-harness warp satin as a non-uneven-surface design portion,thereby obtaining a gray fabric.

Next, by a card cloth raising machine provided with a card cloth rollhaving 12 pile rollers and 12 counter pile rollers, raising wasperformed mainly on the weft to form a napped surface by performingraising thereon 3 times alternately in a weaving end direction and in aweaving start direction at a card cloth roller torque of 2.5 MPa and afabric speed of 12 m/min. Next, the resultant was subjected to a heattreatment by a heat setter at 150° C. for 1 minute and was finished. Thedensity of the warps of the obtained fabric was 184 pieces/25.4 mm, thedensity of wefts was 88 pieces/25.4 mm, and the total fineness per unitvolume 1 mm³ was 4072 dtex.

Next, a polyurethane resin solution (solid content 28 mass %) wasapplied to the entire surface at a fabric speed of 8 m/min by a knifecoater. Clearance conditions were set so that the application amount ofthe polyurethane resin was 25 g/m² in terms of volume after drying.After applying the polyurethane resin solution, the resultant was driedfor 5 minutes in an 80° C. dryer. As the polyurethane resin solution, apolyurethane resin “RYUDTE-W BINDER UF6025” (manufactured by DICCorporation, softening temperature=120° C.) was used.

Next, embossing was performed thereon with an embossing machine at aroll temperature of 120° C., a roll pressure of 1960 N/cm, and a fabricspeed of 3 m/min. As the embossing roll, three types of rollers A to Cdescribed above were used. Next, the resultant was subjected to a heattreatment by the heat setter at 130° C. for 1 minute and was finished.

In the obtained fabric, an uneven-surface design was imparted only tothe napped weft part by the embossing. In the uneven-surface designportion (weft satin portion), the permeation thickness of thepolyurethane resin was 78 μm, the filling ratio of the fibers was 56.2%,the filling ratio of the polyurethane resin was 40.7%, the void ratiowas 3.1%, the ratio between the fibers and the polyurethane resin(fibers/polyurethane resin) was 1.38, the sum of the outercircumferential lengths of the fiber cross-sections per unit area 10,000μm² was 2196 μm. In addition, in the non-uneven-surface design portion(warp satin portion), the permeation thickness of the polyurethane resinwas 199 μm, the filling ratio of the fibers was 36.3%, the filling ratioof the polyurethane resin was 46.8%, the void ratio was 16.9%, the ratiobetween the fibers and the polyurethane resin (fibers/polyurethaneresin) was 0.78, the sum of the outer circumferential lengths of thefiber cross-sections per unit area 10,000 μm² was 1682 μm. The thicknessof the fabric bearing a design was 600 μm.

Evaluation results are shown in Table 1. According to Example 1, thefabric having a unique design in which the uneven-surface design portionhaving a leather-like grain pattern and the non-uneven-surface designportion having the design of the woven structure of the fabric itselfwere repeated in a predetermined pattern over the entire fabric wasobtained.

Examples 2 to 10, Comparative Example 1

Fabrics of Examples 2 to 10 and Comparative Example 1 were produced inthe same manner as in Example 1 except that the configurations anddensities of warps and wefts were changed as shown in Table 1.

Evaluation results are as shown in Table 1. In Comparative Example 1 inwhich threads having the same single fiber fineness were used as thewarp and the weft, an uneven-surface shape formed by embossing wasclearly shaped in both a weft satin portion and a warp satin portion,and thus two types of designs were not obtained, resulting in thedeterioration of design properties. Contrary to this, in Examples 1 to10, fabrics having two types of designs including an uneven-surfacedesign portion to which an uneven-surface design was imparted by theembossing and a non-uneven-surface design portion having the design ofthe woven structure of the fabric itself, on the surfaces of the fabricswere obtained. Particularly, in the fabrics of Examples 1 and 3, thedifference between the uneven-surface design portion and thenon-uneven-surface design portion was clear, and the design propertieswere particularly excellent. Here, in Examples 6 and 8, contrary to theother examples, the warp satin portion became the uneven-surface designportion, and the weft satin portion became the non-uneven-surface designportion.

In addition, in Example 7, the filling ratio of the fibers in theuneven-surface design portion was low, and the wear resistance wasdeteriorated compared to Example 1. In Example 8, the filling ratio ofthe fibers in the uneven-surface design portion was high, and theflexibility was deteriorated compared to Example 1. In Example 10, thevoid ratio in the non-uneven-surface design portion is low, and theuneven-surface shape formed by the embossing was slightly seen even inthe non-uneven-surface design portion. Therefore, the design propertieswere deteriorated compared to Example 1, and the wear resistance wasalso deteriorated compared to Example 1.

Here, the wear resistance was measured according to the wear strength Cmethod (Taber type method) of JIS L 1096 8.19.3 (conditions: abrasivewheel CS-10, load 4.9 N, wear count 1000 times), the specimen after thewear test was observed and evaluated from the viewpoint of whether ornot there is a change in outer appearance, and whether or not theuneven-surface design is unclear or disappears.

Regarding the flexibility, three specimens with a size of 40 mm in widthand 70 mm in length were taken from each of the warp and weftdirections, each of the specimens was bent into two parts in thelongitudinal direction so as to cause the surface thereof to be on theoutside, and was subjected to a bending test 30,000 times underconditions of a gripping interval of 30±0.2 mm, a stroke of 15 mm, and aspeed of 100 times/min in an environment of −10° C., using De Mattiaflexing tester (manufactured by Ueshima Seisakusho Co., Ltd.). Theappearances of the specimens after the bending test were observed andevaluated based on the degree of a change in appearance.

TABLE 1 Example Example Example Example Example Example Example ExampleExample Example Comparative 1 2 3 4 5 6 7 8 9 10 Example 1 Woven fabricWarp Type Multifilament ← ← ← ← ← ← ← ← ← ← false twisted yarn Yarnfineness (dtex) 178 192 150 192 192 167 150 168 150 196 333 Number offilaments (pieces) 24 96 30 96 96 144 72 144 72 48 288 Single fiberfineness (dtex) 7.42 2.00 5.00 2.00 2.00 1.16 2.08 1.17 2.08 4.08 1.16Weft Type Multifilament ← ← ← ← ← ← ← ← ← ← false twisted yarn Yarnfineness (dtex) 333 216 360 275 330 140 330 150 330 330 333 Number offilaments (pieces) 288 144 2400 172 288 72 288 72 288 288 288 Singlefiber fineness (dtex) 1.16 1.50 0.15 1.60 1.15 1.94 1.15 2.08 1.15 1.151.16 Warp density (pieces/25.4 mm) 184 130 180 130 130 174 130 184 133133 184 Weft density (pieces/25.4 mm) 88 94 105 90 76 75 67 75 88 88 88Fabric thickness (mm) 0.60 0.50 0.80 0.50 0.70 0.50 0.60 0.50 0.50 0.600.60 Total fineness per unit volume 1 mm³ 4072 3564 3189 3914 2814 31152730 3320 3857 3616 5943 (dtex) Uneven- Permeation thickness of 78 82 8580 74 98 81 118 78 78 78 surface polyurethane resin (μm) design Fillingratio of fibers (%) 56.2 57.7 59.5 53.2 48.2 78.0 42.4 82.4 55.8 55.856.2 portion Filling ratio of polyurethane resin (%) 40.7 41.5 38.2 41.647.7 19.8 50.7 16.0 40.7 40.7 40.7 Void ratio (%) 3.1 0.7 2.3 5.2 4.12.3 6.8 1.5 3.5 3.5 3.1 Ratio between fibers/urethane resin 1.38 1.391.56 1.28 1.01 3.94 0.84 5.15 1.37 1.37 1.38 Sum of outercircumferential lengths of 2196 1862 7082 1808 1901 3078 1676 3254 22012201 2196 fiber cross-sections per unit area 10,000 μm² (μm) Non-uneven-Permeation thickness of 199 219 204 219 219 263 219 263 204 178 67surface polyurethane resin (μm) design Filling ratio of fibers (%) 36.320.1 32.9 28.7 30.2 35.8 31.1 35.8 43.6 39.9 48.5 portion Filling ratioof polyurethane resin (%) 46.8 42.2 45.3 42.2 42.2 42.2 42.2 42.2 45.452.1 48.4 Void ratio (%) 16.9 37.6 21.8 29.1 27.5 21.9 26.7 21.9 11.08.0 3.1 Ratio between fibers/urethane resin 0.78 0.48 0.73 0.68 0.720.85 0.74 0.85 0.96 0.77 1.00 Sum of outer circumferential lengths of1682 1688 1743 1688 1688 1001 1459 1001 1216 1122 3831 fibercross-sections per unit area 10,000 μm² (μm) Thickness of fabric bearingdesign (μm) 600 500 800 500 700 500 600 500 500 600 600 EvaluationShaping properties 1 1 1 2 1 1 1 1 1 1 1 items Design properties 1 1 1 21 1 1 1 1 2 3

Example 11

Using each polyethylene terephthalate yarn shown in Table 2 below, astripe pattern tricot knitted fabric including a part (14 wales)composed of L2 and L3 and a part (12 wales) composed of L4 was preparedaccording to the weaves shown in Table 3. Next, the polyurethane resinsolution (solid content 28 mass %) was applied to sinker loop surfaces(L2, L3, and L4) by a reverse coater at a fabric speed of 5 m/minute anda roll rotation speed of 12 m/min. The roll rotation speed conditionswere set so that the application amount of the polyurethane resin was 25g/m² in terms of volume after drying. After applying the polyurethaneresin solution, the resultant was dried for 5 minutes in the 80° C.dryer. As the polyurethane resin solution, the polyurethane resin“RYUDTE-W BINDER UF6025” (manufactured by DIC Corporation) was used.

Next, embossing was performed thereon with the embossing machine at aroll temperature of 160° C., a roll pressure of 490 N/cm, and a fabricspeed of 3 m/min. As the embossing roll, three types of rollers A to Cdescribed above were used. Next, the resultant was subjected to a heattreatment by the heat setter at 130° C. for 1 minute and was finished.

Evaluation results are shown in Table 4. In the obtained fabric, a partformed of a front yarn became an uneven-surface design portion, and anuneven-surface design formed by the embossing was imparted thereto. Inaddition, a part formed of a middle yarn became a non-uneven-surfacedesign portion, and the uneven-surface design formed by the embossingwas not imparted thereto.

Examples 12 to 14

Fabrics of Examples 12 to 14 were prepared in the same manner as inExample 11 except that the configuration and weave of each polyethyleneterephthalate yarn were changed as shown in Tables 2 and 3. Evaluationresults are shown in Table 4.

In Example 12, a double raschel knitted fabric was opened, and thepolyurethane resin solution was applied to a stripe pattern pile surfaceformed by a part (10 wales) constituted by L3 and a part (10 wales)constituted by L4. In the obtained fabric, the part formed by the yarnfed through the reed L3 became an uneven-surface design portion, and anuneven-surface design formed by the embossing was imparted thereto. Inaddition, the part formed by the yarn fed through the reed L4 becomes anon-uneven-surface design portion, and the uneven-surface design formedby the embossing was not imparted thereto.

In Example 13, without opening a double raschel knitted fabric, thepolyurethane resin solution was applied to stripe pattern face groundweave surfaces (L4 and L5) formed by a part (7 wales) constituted by L4and a part (7 wales) constituted by L5. In the obtained fabric, the partformed by the yarn fed through the reed L4 became an uneven-surfacedesign portion, and an uneven-surface design formed by the embossing wasimparted thereto. In addition, the part formed by the yarn fed throughthe reed L5 becomes a non-uneven-surface design portion, and theuneven-surface design formed by the embossing was not imparted thereto.

In Example 14, the polyurethane resin solution was applied to thesurface of a border pattern formed by a part (14 courses) constituted bya face yarn 1 of a double jersey knitted fabric and a part (14 courses)constituted by a face yarn 2. In the obtained fabric, the part formed bythe face yarn 1 became an uneven-surface design portion, and anuneven-surface design formed by the embossing was imparted thereto. Inaddition, the part formed by the face yarn 2 becomes anon-uneven-surface design portion, and the uneven-surface design formedby the embossing was not imparted thereto.

TABLE 2 Example 12 Example 13 double double Example 11 raschel raschelExample 14 tricot (opened) (unopened) double jersey Back yarn TypeMultifilament Multifilament Multifilament Multifilament L1 yarn yarnyarn false face yarn 1 twisted yarn Yarn fineness (dtex) 84 84 84 84Number of filaments (pieces) 36 36 36 144 Single fiber fineness (dtex)2.33 2.33 2.33 0.58 Yarn structure Full set Full set Full set Total of14 yarns Middle yarn Type Multifilament Multifilament MultifilamentMultifilament L2 false yarn yarn false face yarn 2 twisted twisted yarnyarn Yarn fineness (dtex) 167 84 84 84 Number of filaments (pieces) 4836 36 36 Single fiber fineness (dtex) 3.48 2.33 2.33 2.33 Yarn structure14 in 12 out Full set Full set Total of 14 yarns Middle yarn TypeMultifilament Multifilament Multifilament Multifilament L3 false falseyarn false bonding yarn twisted twisted twisted yarn yarn yarn Yarnfineness (dtex) 167 167 33 110 Number of filaments (pieces) 48 288 6 24Single fiber fineness (dtex) 3.48 0.58 5.50 4.58 Yarn structure 14 in 12out 10 in 10 out Full set Total of 28 yarns Front yarn TypeMultifilament Multifilament Multifilament Multifilament L4 false falsefalse false rear yarn twisted twisted twisted twisted yarn yarn yarnyarn Yarn fineness (dtex) 110 167 220 167 Number of filaments (pieces)156 48 288 48 Single fiber fineness (dtex) 0.71 3.48 0.78 3.48 Yarnstructure 14 out 12 in 10 out 10 in 7 in 7 out Total of 28 yarns L5 TypeMultifilament Multifilament yarn false twisted yarn Yarn fineness (dtex)84 220 Number of filaments (pieces) 36 96 Single fiber fineness (dtex)2.33 2.29 Yarn structure Full set 7 out 7 in L6 Type MultifilamentMultifilament yarn false twisted yarn Yarn fineness (dtex) 84 167 Numberof filaments (pieces) 36 48 Single fiber fineness (dtex) 2.33 3.48 Yarnstructure Full set 1 in 6 out

TABLE 3 Example 12 Example 13 double double Example 11 raschel raschelExample 14 tricot (opened) (unopened) double jersey Weave Back yarn L1face yarn 1 1-2/1-0 3-2/2-2/0-1/1-1 4-4/4-4/0-0/0-0 see FIG. 8(a) Middleyarn L2 face yarn 2 1-0/3-3/1-0/3-4 0-1/1-1/2-1/1-1 1-2/1-1/1-0/1-1 seeFIG. 8(b) Middle yarn L3 bonding yarn 1-0/3-4/1-0/3-3 0-1/0-10-1/0-1/1-0/1-0 see FIG. 8(c) Front yarn L4 rear yarn 1-0/3-4 0-1/0-11-1/0-1/0-0/1-0 see FIG. 8(d) L5 1-1/0-1/1-1/0-1 1-1/0-1/0-0/1-0 L61-1/3-2/2-2/0-1 0-0/7-7/7-7/0-0 Course density (number of 62.00 48.0045.00 70.00 courses/25.4 mm) Wale density (number of 30.00 32.00 34.0041.00 wales/25.4 mm) Fabric thickness (mm) 1.00 1.00 11.0 1.10 Totalfineness per unit volume 1 2578 1581 2666 2230 mm³ (dtex)

TABLE 4 Example Example Example Example 11 12 13 14 Uneven-surfacePermeation thickness of 88 80 72 79 design portion polyurethane resin(μm) Filling ratio of fibers (%) 52.3 55.7 52.5 56.1 Filling ratio ofpolyurethane 42.8 40.9 40 40.1 resin (%) Void ratio (%) 4.9 3.4 7.5 3.8Ratio between fibers/urethane 1.22 1.36 1.31 1.40 resin Sum of outercircumferential 2464 2894 2859 2861 lengths of fiber cross-sections perunit area 10,000 μm² (μm) Non-uneven- Permeation thickness of 179 179184 184 surface design polyurethane resin (μm) portion Filling ratio offibers (%) 19.6 24.2 2.3 23 Filling ratio of polyurethane 51.6 50.6 50.350.3 resin (%) Void ratio (%) 28.8 25.2 47.4 26.7 Ratio betweenfibers/urethane 0.38 0.48 0.05 0.46 resin Sum of outer circumferential828 1019 120 1211 lengths of fiber cross-sections per unit area 10,000μm² (μm) Thickness of fabric bearing design (μm) 600 800 11000 700Evaluation items Shaping properties 1 1 1 1 Design properties 1 1 1 1

REFERENCE SIGNS LIST

-   -   1 fabric bearing a design    -   2 uneven-surface design portion    -   3 non-uneven-surface design portion

1. A process for producing a fabric bearing a design partially having an uneven-surface design by embossing, the process comprising: applying a polyurethane resin to a surface of a fabric having, on the surface, a low fineness portion and a high fineness portion having a higher single fiber fineness than that of the low fineness portion; drying the fabric; and performing embossing on the surface of the fabric.
 2. The process for producing a fabric bearing a design according to claim 1, wherein, by performing the embossing, while the uneven-surface design is not imparted to the high fineness portion by the embossing and a non-uneven-surface design portion is formed, the uneven-surface design is imparted to the low fineness portion by the embossing and an uneven-surface design portion is formed.
 3. The process for producing a fabric bearing a design according to claim 1, wherein the low fineness portion includes threads having a single fiber fineness of 1.5 dtex or lower, and the high fineness portion includes threads having a single fiber fineness of higher than 1.5 dtex.
 4. The process for producing a fabric bearing a design according to claim 1, wherein the polyurethane resin is applied so that, in the low fineness portion, a permeation thickness of the polyurethane resin is 40 to 400 μm, a filling ratio of the polyurethane resin is 10% to 55%, and a filling ratio of fibers is 45% to 80%.
 5. The process for producing a fabric bearing a design according to claim 1, wherein the polyurethane resin is applied so that a void ratio in the high fineness portion is 10% or higher and is higher than a void ratio in the low fineness portion.
 6. The process for producing a fabric bearing a design according to claim 1, wherein the polyurethane resin is applied so that the polyurethane resin permeates between the fibers at least in a surface portion of the fabric and the surface of the fabric is formed by the polyurethane resin and the fibers.
 7. A fabric bearing a design comprising: a polyurethane resin which is present on a surface portion of the fabric; and an uneven-surface design portion and a non-uneven-surface design portion on the surface portion, wherein the uneven-surface design portion is constituted by threads having a lower single fiber fineness than that of the non-uneven-surface design portion, and an uneven-surface design is imparted to a surface of the uneven-surface design portion by embossing, and the non-uneven-surface design portion is constituted by threads having a higher single fiber fineness than that of the uneven-surface design portion, and the uneven-surface design is not imparted to a surface of the non-uneven-surface design portion by the embossing.
 8. The fabric bearing a design according to claim 7, wherein adjacent fibers in the uneven-surface design portion are fixed together more firmly than in the non-uneven-surface design portion by the polyurethane resin such that the uneven-surface design is imparted to the uneven-surface design portion by the embossing.
 9. The fabric bearing a design according to claim 7, wherein the uneven-surface design portion includes threads having a single fiber fineness of 1.5 dtex or lower, and the non-uneven-surface design portion includes threads having a single fiber fineness of higher than 1.5 dtex.
 10. The fabric bearing a design according to claim 7, wherein, in the uneven-surface design portion, a permeation thickness of the polyurethane resin is 40 to 400 μm, a filling ratio of the polyurethane resin is 10% to 55%, and a filling ratio of the fibers is 45% to 80%.
 11. The fabric bearing a design according to claim 7, wherein a void ratio in the non-uneven-surface design portion is 10% or higher and is higher than a void ratio in the uneven-surface design portion.
 12. The fabric bearing a design according to claim 7, wherein the polyurethane resin permeates between the fibers at least in a surface portion of the fabric and a surface of the fabric is formed by the polyurethane resin and the fibers.
 13. The fabric bearing a design according to claim 7, wherein a sum of outer circumferential lengths of fiber cross-sections in the uneven-surface design portion is 1500 μm or more per unit area 10,000 μm². 